Photovoltaic systems

ABSTRACT

This invention relates to a photovoltaic (PV) unit adapted to provide wireless power transfer output comprising one or more photovoltaic cells that generate electrical output, and at least one wireless power transfer transmitter coupled to transfer the electrical output via wireless power transfer. Such a PV unit can be provided in combination with a roofing, cladding or siding module. Such a module comprises an underlapping region and an exposed region of an adjacent module when installed on a building surface; and an outer surface and an under surface, wherein the under surface of the underlapping region is profiled to define a pathway for air flow between the module and the building surface.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application claims the benefit of priority to U.S. patentapplication Ser. No. 14/361,424, having a filing date of May 29, 2014,which claims the benefit of priority to international patent applicationnumber PCT/NZ2012/000222, having a filing date of Nov. 30, 2012, whichclaims the benefit of priority to Australian patent application number2011904975, having a filing date of Nov. 30, 2011, and New Zealandpatent application number 596793, having a filing date of Nov. 30, 2011,the complete disclosures of which are hereby incorporated by referencefor all purposes.

FIELD OF THE INVENTION

The present invention relates to photovoltaic (PV) systems andassemblies and their use on roofing products.

More particularly the present invention relates to a method wherebyphotovoltaic wafers, sails, cells, modules or the like (generally termed“cells”) can be linked or coupled upon installation and/or duringinstallation so as to enable a useful electrical output.

BACKGROUND TO THE INVENTION

There are many systems where a substrated PV unit or an unsubstrated PVunit requires an electrical connection to a bus, cable or the like. Aninstance includes PV electricity generating systems reliant upon anarray of PV units whether as standalone arrays or when forming part of,for example, the cladding of a building structure (roof and/or walls).

In many instances the PV unit in whatsoever form it takes (whether standalone or substrated) is subject to weathering at any electricalconnection.

Furthermore, where a plurality of PV units require connection oninstallation, for example when installed as an array on a roof top, itcan be difficult and time consuming to make the numerous wired orotherwise contacting electrical connections required in order to derivea useful output. It is crucial to the functioning of the units thatthese connections are made properly at the outset (i.e. before they aresubject to weathering and environmental degradation), however it is easyto overlook the quality of each individual connection when a largenumber of them need to be made in a short space of time to complete theinstallation.

The present invention has as its object, or in at least someembodiments, advantageously provides:

(a) A PV system, and PV units and/or related procedures, methods,subassemblies and the like which will at least avoid the challenge ofsuch weathering or other environmental degradation,

(b) the connection of PV units into an electricity reticulation system,

(c) the provision of a PV system, and PV units and/or relatedprocedures, methods, subassemblies and the like which have an improvedmeans of electrical connection on installation.

It is therefore a further or alternative object or advantage of thepresent invention to at least provide the public with a useful choice.

In this specification where reference has been made to patentspecifications, other external documents, or other sources ofinformation, this is generally for the purpose of providing a contextfor discussing the features of the invention. Unless specifically statedotherwise, reference to such external documents is not to be construedas an admission that such documents, or such sources of information, inany jurisdiction, are prior art, or form part of the common generalknowledge in the art.

Further aspects and advantages of the present invention will becomeapparent from the ensuing description which is given by way of exampleonly.

SUMMARY OF THE INVENTION

In an aspect the invention relates to a photovoltaic unit adapted toprovide wireless power transfer output comprising: one or morephotovoltaic cells that generate electrical output, at least onewireless power transfer transmitter coupled to transfer the electricaloutput via wireless power transfer.

Preferably the photovoltaic unit is for installation on a roof or asubstrate panel to serve as a roofing product.

Preferably the electrical output is transferred via wireless powertransfer to a load and/or output conductor.

Preferably the wireless power transfer is via capacitive couplingwhereby the wireless power transfer transmitter forms a capacitor with awireless power transfer receiver coupled to (or for coupling to) theload and/or output conductor.

Preferably the wireless power transfer transmitter comprises a capacitorplate. Preferably the capacitor plate has surface texturing.

Preferably the surface texturing is nanoscopic and/or microscopicsurface texturing.

Preferably two or more photovoltaic cells coupled together to generatethe electrical output, wherein the photovoltaic cells are coupledtogether using wireless power transfer.

In an aspect the present invention relates to two or more photovoltaicunits coupled together to generate electrical output, each according tothe photovoltaic units defined herein, wherein the photovoltaic cellsare coupled together using wireless power transfer.

In an aspect the invention relates to a roof or roofing componentcomprising a photovoltaic unit according to photovoltaic units definedherein.

Preferably roof or roofing component further comprising at least onewireless power transfer receiver coupled to (or for coupling to) a loador output conductor for receiving electrical output from the wirelesspower transfer transmitter.

Preferably the wireless power transfer is via capacitive couplingwhereby the wireless power transfer transmitter forms a capacitor withthe wireless power transfer receiver coupled to (or for coupling to) theload and/or output conductor.

Preferably the wireless power transfer transmitter comprises a capacitorplate.

Preferably the capacitor plate has surface texturing.

Preferably the surface texturing is nanoscopic and/or microscopicsurface texturing.

In an aspect the invention relates to a PV unit of any appropriate form(substrated or not) able to be mounted or adapted to be mounted so as toreceive solar energy directly or indirectly and generate an electricaloutput, the apparatus being characterised in that it is able to transferenergy output using wireless power transfer (such as inductive and/orcapacitive coupling), said transfer occurring over an inductive and/orcapacitive transfer region.

Preferably or optionally the projected area of the transfer region isless than 50% of the area of the solar receiving area of the PV unit.

Preferably or optionally the surface area of the transfer region is from5% to 1000%, or from 100% to 800%, or from 200% to 600% of the area ofthe solar receiving area of the PV unit.

Preferably or optionally the surface area of the transfer region is from5% to 1000%, or from 100% to 800%, or from 200% to 600% of the projectedarea of the transfer region.

Preferably or optionally the inductive region is greater than or equalto 0.5% of the area of the solar receiving area of the unit.

Most preferably or optionally an optimum area is provided wherebytransfer losses (such as inductive and/or capacitive transfer losses)are rendered substantially insignificant with respect to the certaintyof the output transfer and the output of the PV unit.

Preferably or optionally the transfer of energy output is achieved byinductive coupling.

Preferably or optionally the transfer of energy output is achieved bycapacitive coupling.

Preferably or optionally inductive and/or capacitive coupling isachieved by the interaction of a transmitter able to transmitenergy/power generated by the PV unit and a receiver able to receive thetransmitted energy.

Preferably or optionally the transmitter is an induction coil or pad.

Preferably or optionally the transmitter is a capacitor plate.

Preferably or optionally the transmitter is mounted on or associatedwith the PV unit. Preferably or optionally the transmitter is housed ina recess on the PV unit.

Preferably or optionally the transmitter is housed in a sealedcontainment on the PV unit.

Preferably or optionally the receiver is connected to a reticulationbus, cable or the like for distributing the electrical output.

Preferably or optionally the PV unit is substrated.

Preferably or optionally the transmitter is mounted on or associatedwith the substrate. Preferably or optionally the transmitter is housedin a recess on the substrate.

Preferably or optionally the transmitter is housed in a sealedcontainment within the substrate.

Preferably or optionally the transmitter is a pad (e.g. implementinginductive and/or capacitive coupling) with nanoscopic and/or microscopicsurface texturing on it.

Preferably or optionally the receiver is a pad (e.g. implementinginductive and/or capacitive coupling) with nanoscopic and/or microscopicsurface texturing on it.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith a single transfer region.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith two transfer regions.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith more than two transfer regions.

In a further aspect the invention consists in PV units linked (forexample neurally) by wireless power transfer (such as inductive and/orcapacitive coupling).

Preferably or optionally the said PV units are photovoltaic cells linkedneurally and mounted upon a substrate panel to serve as a roofingproduct.

In a further aspect of the invention consists in PV units linked (forexample neurally) by wireless energy transfer (such as inductive and/orcapacitive coupling).

Preferably or optionally the said PV units are photovoltaic cells linkedneurally and mounted upon a substrate panel to serve as a roofingproduct.

In another aspect the present invention relates to PV units coupled bywireless power transfer (such as by inductive and/or capacitivecoupling) to a reticulation bus, cable or the like for distributing theelectrical output.

Preferably or optionally the wireless power transfer coupling isachieved by energy transfer occurring over a (e.g. inductive and/orcapacitive) transfer region.

Preferably or optionally the projected area of the transfer region isless than 50% of the area of the solar receiving area of the PV unit.

Preferably or optionally the surface area of the transfer region is from5% to 1000%, or from 100% to 800%, or from 200% to 600% of the area ofthe solar receiving area of the PV unit.

Preferably or optionally the surface area of the transfer region is from5% to 1000%, or from 100% to 800%, or from 200% to 600% of the projectedarea of the transfer region.

Preferably or optionally the transfer region is greater than or equal to0.5% of the area of the solar receiving area of the unit.

Most preferably or optionally an optimum area of the power transferregion is provided whereby inductive transfer losses are renderedsubstantially insignificant with respect to the certainty of the outputtransfer and the output of the PV unit.

Preferably or optionally the wireless power transfer coupling isachieved by inductive coupling.

Preferably or optionally the wireless power transfer coupling isachieved by capacitive coupling.

Preferably or optionally wireless power transfer coupling is achieved bythe interaction of a transmitter able to transmit energy generated bythe PV unit and a receiver able to receive the transmitted energy.

Preferably or optionally the transmitter is an induction coil or pad.

Preferably or optionally the transmitter is a capacitor plate.

Preferably or optionally the transmitter is mounted on or associatedwith the PV unit.

Preferably or optionally the transmitter is housed in a recess on the PVunit.

Preferably or optionally the transmitter is housed in a sealedcontainment on the PV unit.

Preferably or optionally the receiver is connected to a reticulationbus, cable or the like for distributing the electrical output.

Preferably or optionally the PV unit is substrated.

Preferably or optionally the transmitter is mounted on or associatedwith the substrate.

Preferably or optionally the transmitter is housed in a recess on thesubstrate.

Preferably or optionally the transmitter is housed in a sealedcontainment within the substrate.

Preferably or optionally the transmitter is a pad (e.g. implementinginductive and/or capacitive coupling) with nanoscopic and/or microscopicsurface texturing on it.

Preferably or optionally the receiver is a pad (e.g. implementinginductive and/or capacitive coupling) with nanoscopic and/or microscopicsurface texturing on it.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith a single transfer region.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith two transfer regions.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith more than two transfer regions.

In another aspect the present invention relates to PV units connectedwirelessly to a reticulation bus, cable or the like for distributing theelectrical output.

Preferably or optionally the wireless connection is achieved by energytransfer occurring over a wireless energy transfer region.

Preferably or optionally the projected area of the wireless energytransfer region is less than 50% of the area of the solar receiving areaof the PV unit.

Preferably or optionally the surface area of the wireless energytransfer region is from 5% to 1000%, or from 100% to 800%, or from 200%to 600% of the area of the solar receiving area of the PV unit.

Preferably or optionally the surface area of the wireless energytransfer region from 5% to 1000%, or from 100% to 800%, or from 200% to600% of the projected area of the wireless energy transfer region.

Preferably or optionally the wireless energy transfer region is greaterthan or equal to 0.5% of the area of the solar receiving area of theunit.

Most preferably or optionally an optimum area of the power transferregion is provided whereby wireless energy transfer losses are renderedsubstantially insignificant with respect to the certainty of the outputtransfer and the output of the PV unit.

Preferably or optionally the wireless connection is achieved byinductive coupling.

Preferably or optionally the wireless connection is achieved bycapacitive coupling. Preferably or optionally the wireless connection isachieved by the interaction of a transmitter able to transmit energygenerated by the PV unit and a receiver able to receive the transmittedenergy.

Preferably or optionally the transmitter is an induction coil or pad.

Preferably or optionally the transmitter is a capacitor plate.

Preferably or optionally the transmitter is mounted on or associatedwith the PV unit.

Preferably or optionally the transmitter is housed in a recess on the PVunit.

Preferably or optionally the transmitter is housed in a sealedcontainment on the PV unit.

Preferably or optionally the receiver is connected to a reticulationbus, cable or the like for distributing the electrical output.

Preferably or optionally the PV unit is substrated.

Preferably or optionally the transmitter is mounted on or associatedwith the substrate.

Preferably or optionally the transmitter is housed in a recess on thesubstrate.

Preferably or optionally the transmitter is housed in a sealedcontainment within the substrate.

Preferably or optionally the transmitter is a pad (e.g. implementinginductive and/or capacitive coupling) with nanoscopic and/or microscopicsurface texturing on it.

Preferably or optionally the receiver is a pad (e.g. implementinginductive and/or capacitive coupling) with nanoscopic and/or microscopicsurface texturing on it.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith a single wireless energy transfer region.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith two wireless energy transfer regions.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith more than two wireless energy transfer regions.

In a further aspect the invention relates to any assembly and/orsubassembly which inductively and/or capacitively transfers the outputfrom one or more PV units into a reticulation device.

Preferably or optionally the transfer occurs over a transfer region{e.g. implementing inductive and/or capacitive coupling).

Preferably or optionally the projected area of the transfer region isless than 50% of the area of the solar receiving area of the PV unit.

Preferably or optionally the surface area of the transfer region is from5% to 1000%, or from 100% to 800%, or from 200% to 600% of the area ofthe solar receiving area of the PV unit.

Preferably or optionally the surface area of the transfer region from 5%to 1000%, or from 100% to 800%, or from 200% to 600% of the projectedarea of the transfer region.

Preferably or optionally the transfer region is greater than or equal to0.5% of the area of the solar receiving area of the unit.

Most preferably or optionally an optimum area is provided wherebytransfer losses are rendered substantially insignificant with respect tothe certainty of the output transfer and the output of the PV unit.

Preferably or optionally the transfer is achieved by inductive coupling.

Preferably or optionally the transfer is achieved by capacitivecoupling.

Preferably or optionally inductive coupling is achieved by theinteraction of a transmitter able to transmit energy generated by the PVunit and a receiver able to receive the transmitted energy.

Preferably or optionally the transmitter is an induction coil or pad.Preferably or optionally the transmitter is a capacitor plate.

Preferably or optionally the transmitter is mounted on or associatedwith the PV unit.

Preferably or optionally the transmitter is housed in a recess on the PVunit.

Preferably or optionally the transmitter is housed in a sealedcontainment on the PV unit.

Preferably or optionally the receiver is connected to a reticulationbus, cable or the like for distributing the electrical output.

Preferably or optionally the PV unit is substrated.

Preferably or optionally the transmitter is mounted on or associatedwith the substrate. Preferably or optionally the transmitter is housedin a recess on the substrate.

Preferably or optionally the transmitter is housed in a sealedcontainment within the substrate.

Preferably or optionally the transmitter is a pad (e.g. implementinginductive and/or capacitive coupling) with nanoscopic and/or microscopicsurface texturing on it.

Preferably or optionally the receiver is an inductor pad (e.g.implementing inductive and/or capacitive coupling) with nanoscopicand/or microscopic surface texturing on it.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith a single transfer region.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith two transfer regions.

Preferably or optionally the photovoltaic unit is a photovoltaic cellwith more than two transfer regions.

In a further aspect the invention is the use of a photovoltaic device(preferably or optionally on or with cladding or roofing), characterisedin that the photovoltaic device has an alternating current or transientdirect current passing through a zone in proximity to a bus, said busbeing receptive to an wireless power transfer (e.g. inductive and/orcapacitive coupling) from the photovoltaic device produced current tothat zone.

In various aspects, the present invention relates to a PV unit utilisingwireless power transfer used or installed on a roofing, cladding orsiding product which is light weight, easy to install, weatherproof,durable, resistant to environmental wear, and aesthetically pleasing.One embodiment relates to a module that can be used to form aweatherproof covering over top of a building surface. Another embodimentis a module which can, in additional to forming a weatherproof covering,be used as part of a thermal energy recovery or removal system. Yetanother embodiment is a module which can, in addition to forming aweatherproof covering, and optionally in addition to being useful aspart of a thermal energy recovery or removal system, bears an array ofsolar cells to generate electrical energy.

In an aspect the present invention relates to a PV unit utilisingwireless power transfer for installation on a roofing, cladding, orsiding module comprising a plurality of formed surfaces moulded from oneor more polymeric materials, wherein each of the formed surfacescomprise three dimensional surface features, and wherein the formedsurfaces are joined (i.e., integrated together, juxtaposed, or united)without weld lines or injection moulding points.

In one embodiment, each formed surface is a moulded segment along thelength of the module. In one embodiment, the three dimensional surfacefeatures of each of the formed surfaces are the same or different. Inone embodiment, the three dimensional surface features have the same orvariable thickness. In one embodiment, the module is substantially flat.In one embodiment, each formed surface comprises an underlapping regionand an exposed region, wherein the underlapping region is adapted to besubstantially covered by the exposed region of an adjacent module wheninstalled on a building surface.

In one embodiment, the roofing, cladding, or siding module comprises aplurality of formed surfaces moulded from one or more polymericmaterials, wherein each of the formed surfaces comprise threedimensional surface features, and wherein the formed surfaces aresequentially formed in a continuum. In some embodiments, the module isformed as it runs through a continuous forming process (as opposed to adie stamping or injection moulding process). Thus, the formed surfaceswith the three dimensional surface features are sequentially formed inthe continuous forming process.

In an aspect the present invention relates to a PV unit utilisingwireless power transfer for installation on a roofing, cladding, orsiding module comprising: an underlapping region and an exposed region,wherein the underlapping region is adapted to be substantially coveredby the exposed region of an adjacent module when installed on a buildingsurface; and an outer surface and an under surface, wherein the undersurface of the underlapping region is profiled to define a pathway forair flow between the module and the building surface.

In one embodiment, the outer surface of the exposed region comprisessurface ornamentation. In one embodiment, the surface ornamentationresembles asphalt shingles, slate, wooden shakes, concrete tiles, or thelike.

In one embodiment, the outer surface of the exposed region comprises aphotovoltaic cell or device. In one embodiment, the module furthercomprises a solar radiation transmissible film which is overlaid uponthe photovoltaic cell.

In one embodiment, the profile of the underside of the underlappingsurface is patterned in a manner to (1) create turbulence in theairflow, (2) increase the surface area of the module in contact with thepassing airflow compared to a module lacking such a surface pattern, orboth (1) and (2). In one embodiment, the profile of the underside of theunderlapping region comprises a plurality of projections that create atortuous pathway above the actual or notional plane of the buildingsurface. In one embodiment, the profile of the underside of theunderlapping region comprises corrugated form of alternating parallelgrooves and ridges.

In one embodiment, the module is moulded from one or more polymericmaterials. In one embodiment, the one or more polymeric materials areselected from the group consisting of polycarbonate, foamedpolycarbonate, thermoplastic polyurethane (TPU), thermoplastic olefin(TPO), polyvinyl chloride (PVC), aquilobutalstyrene (ABS),styrene-acrylonitrile resin (SAN), thermoplastic rubber, and any otheramorphous or crystalline polymer or combination of polymers. In oneembodiment, the one or more polymeric materials are flame retardant. Inone embodiment, the one or more polymeric materials are weather, hail,ultraviolet, tear, mold and impact resistant.

In one embodiment, the module comprises at least two layers of polymericmaterial, wherein the layers are of the same or different polymericmaterial. In one embodiment, at least one material has high UVresistance. In one embodiment, at least one material has high thermalconductivity. In one embodiment, the module further comprises areinforcement layer.

In one embodiment, the module or the polymer layers can be coloured orcomprise a blend of colours. In one embodiment, the polymer on the outerlayer of the module can be manufactured to mimic traditional roofingproducts. In one embodiment, the polymer on the outer layer of themodule can be coloured to contrast with the colour of the PV cell layerto define an aesthetic feature, e.g. shadows.

In one embodiment, the module comprises a first and a second polymericmaterial. In one embodiment, the first polymeric material has beenfoamed. In one embodiment, the first polymeric material is able tochemically bond with the second polymeric material. In one embodiment,the first polymeric material, the second polymeric material, or bothfurther comprise thermally conductive inclusions. In one embodiment, thethermally conductive inclusions have been blended and/or bonded to acompatible polymer or ionomer prior to mixing with the first polymericmaterial. In one embodiment, the thermally conductive inclusions arealuminum particles. In one embodiment, the second polymeric material canself seal to a penetrative fastener. In one embodiment, the firstmaterial is foamed polycarbonate and the second material isthermoplastic polyurethane.

In one embodiment, the top and bottom sides of the underlapping regioncontain complementary locating elements. In one embodiment, theunderlapping region is profiled to define one or more regions for fixingby a penetrative fastener. In one embodiment, the one or more regionsfor fixing by a penetrative fastener are adapted to receive a nail orscrew gun head to accurately locate the fixing.

In one embodiment, the module has a convex precamber configured to applya pre-load pressure to encourage the edges and bottom surface to contactfirmly onto an adjacent underlapping panel when installed on a building.In one embodiment, the upper surface of the underlapping region, thelower surface of the exposed region, or both, comprise a strip offlexible polymeric material configured to prevent water from penetratingbetween two overlapping modules.

In one embodiment, the module has one or more concertina-shaped featuresto accommodate thermal expansion and contraction between fixing points.

In one embodiment, the upper surface of the underlapping regioncomprises channels configured to receive wires of a photovoltaic array.In one embodiment, the upper surface of the underlapping regioncomprises markings to show the correct position of wires and junctionsfor a photovoltaic array. In one embodiment, the upper surface of theunderlapping region comprises pockets or channels configured to receiveprinted circuit boards (PCB), communication devices, junction boxes,wires, buses, components, cells, and/or diodes of a photovoltaic array.

In one embodiment, the module is manufactured by a continuous formingprocess. In one embodiment, the module is continuously formed into ahorizontal strip capable of extending substantially across an entiresection or width of the building surface to be covered. In oneembodiment, the module is continuously formed into a vertical stripcapable of extending substantially down an entire section or length ofthe building surface to be covered.

In an aspect the present invention relates to a PV unit utilisingwireless power transfer for installation on a roofing, cladding, orsiding assembly comprising a plurality of partially-overlapping modulesthat substantially covers a building surface, wherein each modulecomprises an underlapping region and an exposed region, wherein theunderlapping region is adapted to be substantially covered by theexposed region of an adjacent module when installed on a buildingsurface and the exposed region is adapted to be substantially exposedwhen installed on a building surface; an outer surface and an undersurface, wherein the under surface of the underlapping region isprofiled to define a pathway for air flow between the module and thebuilding surface.

In one embodiment, one or more of the modules comprises a photovoltaiccell or device. In one embodiment, the photovoltaic cell or devices areelectrically connected by continuous bus strips. In one embodiment, thecontinuous bus strips only require one terminating junction point to beconnected on installation. In one embodiment, the air flow between theunderlapping region and the building surface is induced by convection ora fan.

In one embodiment, the modules overlap down the fall of the buildingsurface. In one embodiment, the modules overlap across a buildingsurface. In one embodiment, each module is adapted to be fixablyattached to the building surface by at least one fastening member oradhesive. In one embodiment, at least one fastening member is a nail,staple or screw. In one embodiment, the roofing, cladding, or sidingassembly forms a weathertight seal over the building surface.

In an aspect the present invention relates to a PV unit utilisingwireless power transfer for installation on a system for removing orrecovering thermal energy from a building surface, the system comprisinga building surface; a roofing, cladding, or siding assembly comprising aplurality of partially-overlapping modules that substantially covers thebuilding surface, wherein each module comprises an underlapping regionand an exposed region, wherein the underlapping region is adapted to besubstantially covered by the exposed region of an adjacent module wheninstalled on a building surface and the exposed region is adapted to besubstantially exposed when installed on a building surface; an outersurface and an under surface, wherein the under surface of theunderlapping region is profiled to define a pathway for air flow betweenthe module and the building surface; and a fan adapted to induce the airflow.

In one embodiment, the system further comprises a heat exchanger. In oneembodiment, the heat exchanger is part of an air conditioning system,water heating system, or air or media (e.g., sand, ground glass, orconcrete) heating system.

In an aspect the present invention relates to a PV unit utilisingwireless power transfer for installation on a system for generatingelectricity and recovering or removing thermal energy from a buildingsurface, the system comprising a building surface; a roofing, cladding,or siding assembly comprising a plurality of partially-overlappingmodules that substantially covers the building surface, wherein eachmodule comprises an underlapping region and an exposed region, whereinthe underlapping region is adapted to be substantially covered by theexposed region of an adjacent module when installed on a buildingsurface; and an outer surface and an under surface, wherein the undersurface of the underlapping region is profiled to define a pathway forair flow between the module and the building surface, and wherein theouter surface of the exposed region comprises one or more photovoltaiccells.

In one embodiment, the system further comprises a vent for exhaustingthe air flow. In one embodiment, the system further comprises a heatexchanger adapted to receive the air flow. In one embodiment, the airflow is induced by a fan. In one embodiment, the speed of the fan isproportional to the energy created by one or more PV cells. In oneembodiment, the air flow is reversible in order to heat the roof toremove snow, ice, and/or moisture. In another embodiment, the air flowis able to move air from a warmer section of the roof to a coolersection of the roof. In one embodiment, the system is operable (a) togenerate electricity from the one or more photovoltaic cells and (b) toduct an induced or uninduced air flow to be heated and outputted to theheat exchanger during times of solar absorption or heat transmission bythe modules.

In an aspect the present invention provides a method for simultaneouslygenerating electricity and recovering thermal energy from a buildingsurface, the method comprising inducing an airflow to pass through anair passage between a building surface and an under surface of aplurality of partially-overlapping modules that substantially cover thebuilding surface; and collecting electrical energy from one or morephotovoltaic cells present on an exposed surface of the modulesutilizing wireless power transfer; wherein each module comprises anunderlapping region and an exposed region, wherein the underlappingregion is adapted to be substantially covered by the exposed region ofan adjacent module when installed on a building surface and the exposedregion is adapted to be substantially exposed when installed on abuilding surface; and an outer surface and an under surface, wherein theunder surface of the underlapping region is profiled to define a pathwayfor air flow between the module and the building surface.

In an aspect, the present invention provides a method of manufacture ofa roofing, cladding, or siding module on which a PV unit utilisingwireless power transfer can be installed, the method comprising:providing to a continuous forming machine a feed material able to assumeand retain a form after being moulded between a first forming surfaceand a second forming surface; allowing the formation to take place assuch surfaces are advanced in the same direction; wherein the output isa roofing, cladding, or siding module comprising: an underlapping regionand an exposed region, wherein the underlapping region is adapted to besubstantially covered by the exposed region of an adjacent module wheninstalled on a building surface; and an outer surface and an undersurface, wherein the under surface of the underlapping region isprofiled to define a pathway for air flow between the module and thebuilding surface.

In one embodiment, the feed material comprises a layer of a firstmaterial beneath a layer of a second material. In one embodiment, thefirst material is extruded to a supporting surface of a continuousforming machine, and the second material is extruded to the top surfaceof the feed of first material. In one embodiment, the exposed regioncomprises both materials, and the underlapping region comprises, atleast in part, only one of the materials. In one embodiment, the axis ofadvancement of the materials in the continuous forming machine iscommensurate with the longitudinal axis of the module as it lies withthe longitudinal axis across the fall of a roof to be clad thereby.

In one embodiment the entire roofing, cladding or siding module is madefrom a single material.

In one embodiment the module design features can be achieved bythermoforming, pressing, or other method of forming, either continuouslyor discontinuously wood, metal, concrete, resins, glass, clay,composites or the like.

In an aspect, the present invention provides a method of manufacture ofa roofing, cladding or siding on module on which PV unit utilisingwireless power transfer can be installed, the method comprising:providing a feed material in liquid or viscous form to a mould in amoulding position; allowing the material to be moulded as a segment inthe moulding position; advancing the moulded segment to a positionsubsequent to, yet partially overlapping the moulding position;providing further material in liquid or viscous form to the mouldingposition; allowing the material to be moulded as a further segment inthe moulding position along with, or so as to adhere to, the overlappingsection of the previously moulded segment; wherein the output is aroofing, cladding, or siding module comprising: an underlapping regionand an exposed region, wherein the underlapping region is adapted to besubstantially covered by the exposed region of an adjacent module wheninstalled on a building surface; and an outer surface and an undersurface, wherein the under surface of the underlapping region isprofiled to define a pathway for air flow between the module and thebuilding surface.

In an aspect, the invention relates to a PV unit utilising wirelesspower transfer for installation a roofing, cladding, or siding modulehaving (i) a region to underlap a like or other module and (ii) a regionto overlap a like or other module; wherein the overlap region has on, orat least towards, its upper surface serially formed zones of threedimensional features, such zones being of polymeric material(s) providedas a continuum for that module's zones.

In some embodiments, the polymeric material is a layer over at least oneunderlying layer of polymeric material(s). One or other of the polymericmaterials may include a thermally conductive inclusion. In oneembodiment, each such zone of three dimensional features of an overlapregion and a corresponding part of an underlap region is formedsimultaneously. In one embodiment, the same polymeric material(s)provides each said zone and at least part of the underlap region.

In one embodiment, each region to underlap and each region to overlapare three dimensionally contoured. Such contouring can be through to theunder surface to provide for compatibility in overlap indexing. In oneembodiment, the overlap region on its upper surface is bothdimensionally contoured for aesthetic purposes and provided with zonesof features for solar related functionality purposes, e.g. features forassociation with photovoltaics. In one embodiment, such zones of threedimensional features are mutually juxtaposed or at least mutually close.

In an aspect, the invention relates to a PV unit utilising wirelesspower transfer for installation on a building integrated solar energyrecovery system, the system comprising, including or using a roofing,cladding or siding of modules or the equivalent (“modules”) partiallyoverlapping their adjacent modules down and/or across a building surfaceyet to collect in sunlight either, or both, (a) heat solar energy asheat at least in part to pass to an underlying air flow, and/or (b) togenerate electricity photovoltaically for outputting and consequentialheat at least in part to pass to said underlying air flow. In oneembodiment, the modules, as installed on the building surface, withprofile features of each module, provide an underlying pathway for anairflow to be heated by solar energy absorption and/or transmissionthrough said modules. In one embodiment, as part of the cladding array,photovoltaic devices or functionality included and/or carried by aregion or regions of any one or more module are not overlapped by anadjacent module.

In an aspect, the invention relates to a PV unit utilising wirelesspower transfer for installation on a building integrated solar energyrecovery system to either or simultaneously: (a) generate electricityfrom the photovoltaic array of shingles with a photovoltaicfunctionality; and/or (b) duct heated air (e.g. for heat transferpurposes) from an induced or uninduced air flow under one or moreroofing, cladding or siding modules during times of solar absorptionand/or heat transmission by the modules.

In an aspect, the invention relates to a on PV unit utilising wirelesspower transfer for installation on a roofing, cladding or sidingcomponent suitable or installed to pass solar energy received by atleast some of its regions into an underlying airstream, and with aphotovoltaic regional functionality with a photovoltaic receiving regionto convert received solar energy into an electrical output. In oneembodiment, when as part or as part of a series down or across anunderlying building surface, is useable whereby each photovoltaicreceiving region is fully exposed despite partial overlapping of onecomponent to another to better shed water; and is useable whereby,despite attachment to the underlying building surface, there is a setout from the underlying building surface sufficient to allow a passageof an underlying airstream.

In some embodiments, at least part of the profile of each roofingcomponent has been moulded (i) by a CFT (as herein defined); and/or (ii)to accommodate a photovoltaic functionality; and/or (iii) to accommodateinterconnection functionalities of photovoltaic areas; and/or to defineat least in part said configuration; and/or (iv) to be very much greaterin dimension across the building surface to be covered than thedimension it will cover down said building surface; or (v) to be verymuch greater in dimension down the building surface to be covered thanthe dimension it will cover across said building surface.

In some embodiments, the dimension of the module in the direction thatextends across the building surface is at least 3 times, or at least 4times, or at least 5 times, or at least 10 times, or at least 15 times,or at least 20 times that of the dimension of the module that extendsdown the building surface. In some embodiments, the dimension of themodule in the direction that extends down the building surface is atleast 3 times, or at least 4 times, or at least 5 times, or at least 10times, or at least 15 times, or at least 20 times that of the dimensionof the module that extends across the building surface.

In a further aspect, the invention relates to a on PV unit utilisingwireless power transfer for installation on a roofing, cladding orsiding module or equivalent (“module”) comprising or including amoulding of a first material and a second material; wherein the firstmaterial defines a first region or first regions (“first region(s)”) anda second or second regions (“second region(s)”), whether profiled ornot; and wherein the second material defines an overlay or underlay ofat least part of one of said first and second regions; and wherein aplurality of said modules lapping their neighbour down or across abuilding surface with a notional or actual planar surface to be overcladby such a series of modules to form a weathertight seal over saidbuilding surface.

In a further aspect, the invention relates to a on PV unit utilisingwireless power transfer for installation on a roofing, cladding orsiding assembly comprising or including a structure to provide a supportsurface, and a plurality of modules to cover the underlying supportsurface, the modules relating to any neighbour(s) in an overlappingarrangement down the fall or pitch of the underlying surface, thereby todefine the exterior fall or pitch of the roofing, cladding or sidingassembly; wherein at least some of the modules include photovoltaic(“PV”) devices exposed to sunlight able to generate an electricaloutput; and wherein the plurality of modules define a pathway above thesupport surface for an air flow, induced or otherwise, to be heated byheat exchange from at least some of the modules as a consequence ofheating of the modules by received sunlight or heating of the modules asa consequence of the effect of received sunlight on the PV devices, orboth.

In a further aspect, the invention relates to a on PV unit utilisingwireless power transfer for installation on a roofing, cladding orsiding assembly as herein described to either or simultaneously: (a) togenerate electrical output from said PV devices; and/or (b) heat aninduced or other air flow by heat exchange from at least some of themodules as a consequence of heating of the modules by received sunlightor heating of the modules as a consequence of the effect of receivedsunlight on the PV devices, or both.

In a further aspect the invention relates to a on PV unit utilisingwireless power transfer for installation on a roofing, cladding orsiding component, or substrate therefor, which comprises or includes thesteps of: providing to at least one of the forming surfaces of acontinuous or discontinuous forming machine a feed of material able toassume and retain a form after being moulded between that firstmentioned forming surface and a second forming surface, and allowingthat formation to take place as such surfaces are advanced in the samedirection; wherein the output is of a form having a profiled region tostep out part of that region from an underlying actual or notionalplanar surface, yet providing another region to, at least in part,overlap said profiled region of a like form.

In a further aspect, the invention relates to a on PV unit utilisingwireless power transfer for installation on a roofing, cladding orsiding component, or substrate therefor, which comprises or includes thesteps of: providing material in liquid or viscous form to mould in amoulding position; allowing said material to be moulded as a segment insaid moulding position; advancing said moulded segment to a positionsubsequent to, yet partially overlapping said moulding position;providing further material in liquid or viscous form to the mouldingposition; allowing said material to be moulded as a further segment inthe moulding position along with, or so as to adhere to, the overlappingsection of the previously moulded segment; wherein the output is of aform having a profiled region to step out part of that region from anunderlying actual or notional planar surface, yet providing anotherregion to, at least in part, overlap said profiled region of a likeform.

In a further aspect, the invention provides a method of manufacture of aroofing, cladding or siding component, or substrate therefor on which PVunit utilising wireless power transfer can be installed, which comprisesor includes the steps of: (1) extruding or otherwise providing a feed ofa first material to a supporting surface of a continuous formingmachine, the feed having a width WI and thickness T; (2) extruding orotherwise providing a feed of a second material to the top surface ofthe feed of first material, the feed having a width WII and thicknessTII; (3) allowing the two materials to be formed; and wherein the outputis of a form having a first profiled region to step out part of thatregion from an underlying actual or notional planar surface, yetproviding a second region to, at least in part, overlap said profiledregion of a like form; and wherein said second region is covered by bothmaterials, and said profiled region is covered, at least in part, byonly one of the materials. In one embodiment, the axis of advancement ofthe materials in the continuous forming machine is commensurate with thelongitudinal axis of a roofing shingle that is to lie with saidlongitudinal axis across the fall of a roof to be clad thereby.

In a further aspect, the invention relates to a on PV unit utilisingwireless power transfer for installation on a roofing, cladding orsiding component, or substrate of a roofing, cladding or sidingcomponent including product having a first region and a second region,the component to be used as a covering across the fall of a buildingstructure and to overlap at least in part with its first region, and tounderlap at least in part with its second region, the first and secondregions of a like component or substrate; wherein the component has beenformed by a feed of materials into a continuous forming machine toprofile at least one or either, or both, of the first and second regionsor at least parts thereof; and wherein the advance direction of thecontinuous forming machine defines the elongate axis of the componentthat is to lie across the fall of the building surface.

In another aspect, the invention relates to a PV unit utilising wirelesspower transfer for installation on a roofing, cladding or siding moduleadapted to be fixed with its elongate axis across the fall of thebuilding surface to be clad; the module having a first longitudinalregion to underlie, in use, a like module or flashing, and a secondlongitudinal region, in use, to overlie a like module or to simply beexposed; wherein the first and second regions share in common a firstmaterial; and wherein the first and second regions share in common asecond material, yet the second region has its upper surface defined bya second material while only part of the first region (i.e. that part ofthe first region proximate to the second region) has its upper surfacedefined by said second material; and wherein there has been such sharingof the first and second materials since a continuous forming process;and wherein one, some or all of the following apply: (i) at least theunderside of the first region defines a profile of projections (e.g.mesa-like or otherwise) to stand the remainder of the first region offfrom an actual support or notional support plane; (ii) such projectionsdefine a tortuous pathway above the actual or notional plane; (iii) thetopside of the first region, with depressions, provide a female versionof the male underside; (iv) the second material is weather resistant;(v) the first material has been foamed; (vi) the first material includesparticulate thermally conductive inclusion; (vii) the second materialcan self seal to a penetrative fastener; (viii) the first material is apolymeric material, the second material is a polymeric material, atleast the upper surface of the second region has been profiled; (ix) theupper surface of the second region has been profiled to simulateconventional roofing products (e.g. tiles, slate, shingles shakes or thelike); (x) the upper surface of the second region channels, pockets orthe like to accommodate or accommodating the buses and/or cells of aphotovoltaic array; (xi) the first and second materials have beencoextruded or serially extruded into a continuous forming machine; and{xii) the extrusion has been into an advancing continuous formingmachine where the elongate axis is aligned to the advancement.

In a further aspect, the invention relates to a PV unit utilisingwireless power transfer for installation on a roofing shingle, tile orequivalent module {“shingle”) substantially as herein described, with orwithout reference to the accompanying drawings.

In a further aspect, the invention relates to a PV unit utilisingwireless power transfer for installation on a roof assemblysubstantially as herein described, with or without reference to theaccompanying drawings.

In a further aspect, the invention relates to a PV unit utilisingwireless power transfer for installation on a building integrated solarenergy recovery system substantially as herein described, with orwithout reference to the accompanying drawings.

In a further aspect, the invention relates to a PV unit utilisingwireless power transfer for installation on a roof clad by roofingcomponents of any aspect of the present invention.

In a further aspect, the invention relates to a PV unit utilisingwireless power transfer for installation on a building surface clad bycladding or siding components of any aspect of the present invention.

As used herein the term “and/or” means “and” or “or”, or both.

As used herein “(s)” following a noun means the plural and/or singularforms of the noun.

The term “comprising” as used in this specification means “consisting atleast in part of”. When interpreting statements in this specificationwhich include that term, the features, 10 prefaced by that term in eachstatement, all need to be present but other features can also bepresent. Related terms such as “comprise” and “comprised” are to beinterpreted in the same manner.

As used herein the term “object” denotes a possible purpose or utilityfor the invention described but such a purpose or utility need not beconstrued as a mandatory feature of the invention.

The term “PV unit” includes photovoltaic or photoelectric wafers, sails,cells, arrays and modules (themselves generally termed “cells”), assingle items and/or multiple groupings of such items, and assembliesand/or subassemblies comprising any or all of these items or groupingsof items.

The term “wireless power transfer” (also termed “AC coupling”) includespower transfer by inductive coupling, resonant inductive coupling,capacitive coupling and all other methods of wireless energy/powertransfer.

The term “wireless power transfer” and “wireless energy transfer” can beused interchangeably in a general sense to denote transfer via some typeof AC or other wireless coupling (such as inductive and/or capacitivecoupling).

Relative terms, such as “lower” or “bottom”, “upper” or “top,” and“front” or “back” may be used herein to describe one element'srelationship to another element as illustrated in the Figures. It willbe understood that relative terms are intended to encompass differentorientations of the device in addition to the orientation depicted inthe Figures. For example, if the device in one of the figures is turnedover, elements described as being on the “lower” side of other elementswould then be oriented on “upper” sides of the other elements. Theexemplary term “lower”, therefore, encompasses both an orientation of“lower” and “upper,” depending of the particular orientation of thefigure. Similarly, if the device in one of the figures is turned over,elements described as “below” or “beneath” other elements would then beoriented “above” the other elements. The exemplary terms “below” or“beneath” can, therefore, encompass both an orientation of above andbelow.

As used herein, the term “formed surface” refers to a moulded segment ofa polymeric material corresponding to an individual dye or mold of acontinuous forming machine.

As used herein, the term “building surface” refers to a wall surface ora top surface, etc. of a building, e.g. an exterior wall, a roof, aceiling, etc., unless otherwise specified. In the context of a roof, thebuilding surface typically comprises a waterproof roofing membraneattached to the roof deck adjacent an eave of the roof for preventingwater damage to the roof deck and an interior of a building fromwind-blown rain or water buildup on the roof. The roof deck is typicallymade of an underlying material, such as plywood. The waterproof membranemay be any of a number of waterproof roofing membranes known in the artsuch as but not limited to bituminous waterproof membranes, modifiedbituminous roofing membranes, self-adhering roofing membranes, or singleply waterproofing roofing membranes (e.g. EPDM waterproof roofingmembranes, PVC waterproof roofing membranes, TPO waterproof roofingmembranes). One exemplary membrane sheet is Deck-Armor™ Roof Protection,manufactured by GAF Corp., Wayne, N.J.

As used herein, the term “roofing” means the provision of a protectivecovering on the roof surface of a building. Without limitation, such aprotective covering might take the form of shingles, tiles, panels,shakes, planks, boards, modules, mouldings or sheets.

As used herein, the terms “cladding” and/or “siding” mean the provisionof a protective covering on a side or other surface of a building.Without limitation, such a protective covering might take the form ofshingles, tiles, panels, shakes, planks, boards, modules, mouldings orsheets.

As used herein, the terms “profiled” and/or “contoured” mean having aregion, or regions which extend above or below a notional planar surfacelying along the longitudinal axis of the product. This includesprofiling or contouring of only one upper or lower surface, and/orprofiling or contouring of an entire thickness of material such that theupper and lower surfaces have the same relative degree of extensionabove or below the notional planar surface.

As used herein, the term “thermally conductive particles” or “thermallyconductive inclusions” refers to particles or inclusions of anyconductive material. These include, but are not limited to, particles ofthe following materials: metals, metal hybrids, carbon, silica, glass,conductive polymers, salts, carbon nanotubes and compounds of thesesubstances. In addition to assisting in heat transfer, the thermallyconductive particles or inclusions may also act as a reinforcingmaterial.

As used herein, the term “polymer” (and associated terms such as“polymeric”) includes polymers, polymer blends, and polymers with orwithout additive inclusions.

This invention may also be said broadly to consist in the parts,elements and features referred to or indicated in the specification ofthe application, individually or collectively, and any or allcombinations of any two or more said parts, elements or features, andwhere specific integers are mentioned herein which have knownequivalents in the art to which this invention relates, such knownequivalents are deemed to be incorporated herein as if individually setforth.

The invention consists in the foregoing and also envisages constructionsof which the following gives examples only.

The entire disclosures of all applications, patents and publications,cited above and below, if any, are hereby incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described by way ofexample only and with reference to the drawings, in which:

FIG. 1 shows a typical glass solar panel carrying photovoltaic cells andhaving a series of inductive power transfer zones down one side of thepanel.

FIG. 2 is a close up view of the cells shown in FIG. 1.

FIG. 3 is a view of the solar panel of FIGS. 1 and 2 showing the mainpower take off cable running down the underside of the panel.

FIG. 4 shows a sectional view of some preferred components as arrangedto achieve inductive power transfer of the energy produced by a PV cell.

FIG. 5A shows a glass solar panel carrying photovoltaic cells, each ofwhich is connected to a power generation and output system by twoinductive power transfer zones.

FIG. 5B shows the reverse side of the panel shown in FIG. 5A.

FIG. 6 shows a formed substrate carrying an array of PV cells, andhaving at one end a device for the inductive transfer of energy from thePV cells to a receiver able to receive the transmitted energy.

FIG. 7 shows a series of formed substrate panels, each carrying an arrayof PV cells and each having at one end a device for inductive powertransfer, as assembled on a roof top, each inductively connected to amain reticulation bus running down the edge of the roof.

FIG. 8 is an exploded view of FIG. 7.

FIG. 9 shows one embodiment whereby two PV modules are electricallyconnected with an inductive connection.

FIG. 10 shows in schematic form the electrical arrangement of a PV unitwith wireless power transfer.

FIG. 11 shows an illustrative embodiment of a continuously formedroofing, cladding or siding module in its basic form.

FIG. 12 shows an illustrative embodiment of a continuously formedroofing, cladding or siding module fixed in an overlapping arrangementupon a building surface.

FIG. 13 shows the underlapping, exposed and fixing regions of anillustrative embodiment of the roofing module.

FIG. 14 shows an embodiment of the module having been formed to have asinusoidal profile to simulate concrete tiling.

FIG. 15 shows an embodiment of the module having been formed to have ajagged profile to simulate weatherboarding.

FIG. 16 shows an embodiment of the module having been formed to haverelief contours on its upper surface to simulate asphalt shingle.

FIG. 17 shows a series of modules fixed in a lapping arrangement withoffset vertical alignment for added visual appeal.

FIGS. 18A-18C show the detail of the fixing region of one embodiment ofthe module and the locators through which fasteners can be driven tosecure the module to the building surface.

FIG. 19 shows a nail type fastener sitting within a locator recesssealed off by an overlapping module.

FIG. 20 shows an illustrative embodiment of the roofing module which hasbeen moulded to have a precamber.

FIG. 21A shows an embodiment of the module which includes adhesivestrips for securing the modules to create a weathertight seal.

FIG. 21B shows an exploded view of the module of FIG. 21A.

FIG. 22 shows an embodiment of the module where a first adhesive stripis affixed along the lower edge of the module on the back side of themoulded material layer, while a second is affixed to the top side justbelow the line of the fixing region.

FIG. 23A shows an alternative embodiment wherein the adhesive strips arepositioned so that both strips are on the front of the module; one atthe rear edge and one just below the line of the fixing region. FIG. 23Bshows an embodiment where a strip of material on the upper surface ofthe underlapping region serves as a weather-tight barrier.

FIG. 24 shows diagrammatically a continuous forming apparatuscontemplated as providing for the continuous forming of various modulesdescribed herein.

FIG. 25 shows a module wherein a second layer of material has beenformed overtop of, but not entirely covering, a first layer of material.

FIG. 26 shows an illustrative embodiment of a module wherein athermoplastic polyurethane layer has been formed along with, and on topof, a foamed polycarbonate layer, to give product characteristicsdesirable for a roofing shingle.

FIG. 27 is an exploded view of a roofing assembly to be used in thecollection of thermal and/or solar energy.

FIG. 28A is a side on view of the module assembly of FIG. 27.

FIGS. 28B-28C shows a cross-section of the module and air filter at theedge of a building surface.

FIG. 29 is a diagram showing how heat recovered from the roofing systemcan be collected and used.

FIG. 30 shows a cross section of a profiled feature moulded as part ofthe underlapping region of a module.

FIG. 31A shows the underside of a module with projection featuresincluded to encourage turbulent flow of the underpassing air stream.

FIG. 31B shows a module surface (as seen in FIG. 31A) with a series offine ribs integral to the moulding so as to increase the module'scontact surface with the air stream and assist heat transfer.

FIG. 31C is a close up view showing the profile of the ribs of FIG. 21B.

FIG. 32 shows two modules positioned in a lapping arrangement and havingcomplementary surface textures on their respective contact surfaces.

FIG. 33 shows an overlapping series of one embodiment of the moduledesigned to carry a solar array for photovoltaic power generation.

FIG. 34 is a detailed view of the module of FIG. 33.

FIG. 35 shows a method of endwise joining two modules with an overlaidsolar panel secured across the joining region.

FIG. 36A shows the detail of the relief features on the surface of thebuilding integrated photovoltaic embodiment of the module which aredesigned to locate a series of electrically connected photovoltaiccells.

FIG. 36B shows the detail of the channels configured to receive cablesor wires of the photovoltaic array cavities configured to receivejunction boxes. This figure also shows surface marking to indicate thelocation position of the underlying electrical fittings and connections.

FIG. 37 shows diagrammatically a continuous forming apparatuscontemplated as providing for the continuous forming of modules andlending itself to the online introduction downstream of a photovoltaicfunctionality system.

FIG. 38 shows a building on which various embodiments of the currentinvention have been installed.

FIG. 39A shows the detail of a concertina feature designed toaccommodate thermal expansion and contraction of the module.

FIG. 39B shows the detail of the concertina feature placed between twofixing points.

FIG. 40 shows a “dummy” module positioned in a lapping arrangement witha cutout for a pipe emerging from the building surface. BIPV modules areshown on either side of the “dummy module”.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A first embodiment of the invention is shown in FIG. 1 wherein an arrayof solar (PV) cells 001 are mounted on a typical glass solar panel 002and wired in parallel to pairs of positive 201 and negative 202 cablesrunning across the width of the panel (as can been seen more clearly inFIG. 2). Together they form a PV unit and generate electrical/poweroutput (such as output voltage and/or current) at e.g. the right handend of each cable there is a wireless power transfer (e.g. inductiveand/or capacitive) transmission device (transmitter) 203 which may ormay not be recessed or encapsulated into the glass. There may be aseparate transmission device for each cable, or they may be shared asshown in FIG. 2. The transmitter can transmit power to a reciprocalreceiver on a load and/or output conductor.

For example, a main power take off cable/conductor (which can connect toa load) 301 runs on the underside of the panel in the verticaldirection, and there are respective/reciprocal wireless power transfer(e.g. inductive and/or capacitive) receiving devices or means (receiver)302 spaced at intervals along this cable. This can be seen in FIG. 3.The transmitter 203 and receiver 302 work co-operatively to providewireless power transfer. The takeoff cable can be installed prior to thesolar panel and connected as required to other devices which willeventually draw power from the solar module/panel.

When the solar panel is installed (for example on a roof or otherexterior building surface) all that is required is to align thetransmission device(s) 401 with the receiving device(s) 402. Becausethere does not need to be direct physical contact between thetransmission device and the receiving device, the transmission device401 can be housed within a recess 403 integral to the form of the glasspanel as shown in FIG. 5. Similarly there may be features or markers inthe underside of the panel 404 to house the receivers on installationand to assist in locating them correctly.

Housing the transmitting and receiving components in recesses alsoprotects them from weathering, abrasion and impact, and will help toreduce the instance of failure of the power generation system at theelectrical connection points. It may be that the transmission device andassociated components are completely concealed within the substrate forthis purpose.

The surfaces of the transmission device 405 and the receiving device 406should be positioned in close proximity to one another, for example, asshown in FIG. 4. This means that no electrical connections need be madeonce the system components are in position, and also that a small degreeof misalignment and/or non-contact at the electrical connection pointscan be tolerated.

The components of the transmission device itself may take a number offorms depending on the wireless power transfer method employed, as willthe form of the receiving device; however in one embodiment both thetransmitter and receiver are coils or pads which together form aninductive or capacitive coupling. n capacitive coupling, the transmitterand receiver together form a capacitor. Each, for example, may take theform of a respective capacitor plate.

Where the transmitter and receiver are pads or plates, microscopicand/or nanoscopic or other surface texturing can be applied to the padsurfaces (for example surfaces 405 and 406) to increase the surface areaof the pad or plate, and therefore aid in the efficiency and/or rate ofwireless power transfer. In one embodiment the surfaces may be patternedor profiled with a high ratio aspect pattern (for example, by a seriesof finely pointed peaks).

A device, possibly an intermittent switching device, may be required toconvert the direct current output from the solar cells to alternatingcurrent prior to transmission through the coupling.

A second arrangement is as shown in FIGS. SA and SB, wherein there is anarray of solar (PV) cells 501, each having its own wireless powertransfer means. n this arrangement there are a networked series ofpower-takeoff cables 502 running across the solar array. There may beone or more wireless power transfer zones (e.g. inductive and/orcapacitive) 503 on each cell depending on the wiring configuration. Theconnection density should be selected according to the useful poweroutput requirements of the system.

A further and preferred embodiment of a unit having a region able to becapacitively or inductively used to transfer output power from a PVdevice is as shown in FIG. 6. A formed substrate panel 601, of the sortwhich can be mounted on the roof top of a building, bears a plurality ofphotovoltaic cells 602 which are electrically connected to a singleoutput terminal at one side of the panel. At the output terminal thereis a device for inductive or capacitive power transfer 603 to areceiving conductor.

The substrate panel, or a series of such panels, can then be installedupon a roof or other surface exposed to solar energy, along with one ormore wireless transfer power receiver(s). The receiver(s) are in turnconnected to a power distribution network so that the electrical energycan be directed as required.

The preferred method of assembly for a power generation systemincorporating the photovoltaic unit described is shown in FIG. 7,wherein a number of substrate panels 701 are fixed down the fall of aroof. Each panel has, at e.g. its right hand end, a device 702 forwireless power transfer of the energy collected by the solar cellsmounted upon it to a single output 703.

FIG. 8 is an exploded view of the assembly of FIG. 7, which shows thatrunning down the e.g. right hand side of the fall of the roof, butunderlying the panels, is a main electrical bus strip 801. The bus strip(by itself or by way of connected receiver devices) is able to receivethe energy transmitted by the wireless power transfer devices on each ofthe substrate panels. The energy is then distributed, via the bus strip,as useful electrical output.

The positioning of the receivers (if any) along the bus strip can becalculated before the bus strip is installed on the roof. Subsequentlythe panels can be affixed onto the roof so that the correspondingtransmission zones and receiving zones are aligned. The substrate panelmoulding may also have features 802 to aid in the location of thetransmitter respective to the receiver.

As discussed, it is also particularly advantageous to be able towirelessly (e.g. inductively and/or capacitively) make connectionsbetween adjacent PV units as they are installed on a roof or buildingsurface. It is possible to do this by providing correspondingtransmitting and receiving regions on each adjacent module and theninstalling the modules so that the transmitter and receiver regions areoverlaid. The embodiment shown in FIG. 9 gives an example of howwireless joining of adjacent modules can be achieved by laying aconnector cell 901 over top of the join between the modules that two ormore power transfer regions 902 of the connector cell are in closeproximity to one or more power transfer regions of the each of themodules. The connector cell may be a functional solar cell, or may justbe a cell without PV functionality which merely serves as a conductor.Concealing the joint between the modules with the connector cell can bean aesthetic improvement compared to installing a series or array ofmodules with visible join lines between them. Individual PV cells of aPV unit can also be coupled by wireless power transfer to produceoutput.

FIG. 10 shows in schematic form the invention. A PV unit is coupled to awireless power transfer transmitter (e.g. inductor coil or capacitorplate) which is inductive and/or capacitively coupled to a reciprocalwireless power transfer receiver (e.g. conductor coil or capacitorplate) which itself is coupled to a load directly or via an outputconductor.

In one embodiment, the PV system/unit described can be installed on aBIPV roofing system/product as described below.

In some embodiments, the roofing product comprises modules having g aplurality of formed surfaces moulded from one or more polymericmaterials (which may be in layers), wherein each of the formed surfacescomprises three dimensional surface features. The present technologyalso relates to a product having good thermal conductivity and acapacity for photovoltaic (“PV”) and/or solar thermal energy generation,and related subassemblies, assemblies, uses and methods. The presenttechnology has several advantages. For example, the roofing, cladding orsiding product may reduce the amount of heat energy transferred to theinterior of the building upon which it is mounted; and/or to provide asystem which incorporates a roofing, cladding or siding product to thateffect; and/or to provide a method by which mass production of such aproduct could be achieved; or at least provides the public with a usefulchoice.

In embodiments a Building Integrated Photovoltaic (“BIPV”) and/or solarthermal roofing, cladding or siding product is provided which isreasonably light weight easy to install, durable and resistant toenvironmental wear; or at least provides the public with a usefulchoice.

In other embodiments, a BIPV and/or solar thermal roofing, cladding orsiding product is provided that does not require a fastener (nail,screw, bolt, etc.) to penetrate the exposed surfaces of the roof,thereby making the product less likely to leak compared to convention BPV products; or at least provides the public with a useful choice.

In other embodiments, a BIPV and/or solar thermal roofing, cladding orsiding product is provided capable of large surface area coverage, thatcan be mass produced in high volumes and with reasonable speed ofproduction; and/or to provide a method by which such mass production ofsuch a product could be achieved; or at least provides the public with auseful choice.

In other embodiments, a BIPV and/or solar thermal roofing, cladding orsiding product is provided which will allow heat energy to betransferred away from the photovoltaic cell to maximise its operationalefficiency; and/or to provide a system which incorporates a BIPVroofing, cladding or siding product to that effect; and/or to provide amethod by which mass production of such a product could be achieved; orat least provides the public with a useful choice.

In other embodiments, an airway path is provided to allow space forwires and other electrical components to run between the roof and thebuilding structure with such wires and electrical components locatedabove a waterproof membrane on the building substrate surface thereforeensuring that the waterproof membrane is not penetrated.

In yet other embodiments, a building integrated system is provided whichallows solar, ambient and photovoltaically generated heat to betransferred away from a building surface and used elsewhere; and/or thecomponents of such a system; and/or a method of manufacturing suchcomponents; or at least provides the public with a useful choice.

Various embodiments relate to a roofing, cladding or siding product tobe secured to a building in a lapping arrangement. In one embodiment theproduct is formed as a module to be laid horizontally across a surfaceand lapped vertically down that surface, however, it is also possible tomanufacture the product so as to allow it to be laid in vertical columnswhich would then lap across the surface. In particular, threeillustrative embodiments of the product are described below. The firstis a module which can be used to form a weatherproof covering over topof a building surface; the second is a module which can, in additionalto forming a weatherproof covering, be used as part of a thermal energyrecovery system; and the third is a module which can, in addition toforming a weatherproof covering, and optionally in addition to beinguseful as part of a thermal energy recovery system, bears an array ofsolar cells to generate electrical energy.

In one aspect, a roofing, cladding or siding product is provided whichis reasonably light weight, easy to install, durable and resistant toenvironmental wear. In some embodiments, the roofing, cladding or sidingproduct is capable of large surface area coverage, can be mass producedin high volumes and with reasonable speed of production; and/or providesa method by which such mass production of such a product can beachieved.

In one embodiment, the roofing, cladding or siding product is a modulecomprising a plurality of formed surfaces moulded from one or morepolymeric materials (which may be in layers), wherein each of the formedsurfaces comprises three dimensional surface features, and wherein theformed surfaces are joined without weld lines or injection mouldingpoints. Each formed surface refers to a moulded segment along the lengthof the module that corresponds to an individual dye or mold of acontinuous forming machine. See PCT/NZ2006/000300 (published asWO2007/058548). Use of the term “joined” in this context is not intendedto require that each of the formed surfaces were ever separated, i.e.,the formed surfaces may be integrally formed together in situ during themanufacturing process. In another embodiment, the module design featurescan be achieved by thermoforming, pressing, or other method of forming,either continuously or discontinuously wood, metal, concrete, resins,glass, clay, composites or the like.

In particular, the product can be manufactured in long strips (as seenin FIG. 11) by a continuous process which incorporates a continuousforming step, and therefore can be made in varying lengths as requireddepending on the required coverage area. Production is such that asingle moulded module, capable of extending across the entire width orsection of the roof or building to be protected, can be manufactured.For example, the modules may be very much greater in dimension acrossthe building surface to be covered than the dimension it will cover downthe building surface. In one embodiment, the dimension of the module inthe direction that extends across the building surface is at least 3times, or at least 4 times, or at least 5 times, or at least 10 times,or at least 15 times, or at least 20 times that of the dimension of themodule that extends down the building surface. Alternatively, themodules may be very much greater in dimension down the building surfaceto be covered than the dimension it will cover across the buildingsurface. In one embodiment, the dimension of the module in the directionthat extends down the building surface is at least 3 times, or at least4 times, or at least 5 times, or at least 10 times, or at least 15times, or at least 20 times that of the dimension of the module thatextends across the building surface.

In some embodiments, the modules are about 0.2-1 in length, 1-20 metresin length, about 3-10 metres in length, or about 4-8 metres in length,or 2-4 metres in length. Modules of 4-5 metres in length, and modules of8 metres in length are suitable manufacturing sizes, but themanufacturing process allows custom lengths to be accommodated just aseasily. A plurality of such modules can then be arranged in lapping rowsdown the surface of the structure, for example, as shown by the lappingroof shingles seen in FIG. 12.

The features of an illustrative embodiment of the basic roofing productare as shown in FIG. 13. There is an underlapping region 1301, and anexposed region 1302 (i.e. to be exposed when a series of modules arepositioned in a lapping arrangement). There may also be a fixing region1303 where the module 1300 is to be attached to the building surface,and this may or may not be within the underlapping region 1301, but issuitably or optionally within the underlapping region 1301. The regionsmay exist in various proportions comparative to each other, and theremay be profiling or contouring 1304 of any or all regions in acontinuous or discontinuous pattern along the length of the module 1300.In one embodiment, the width of the underlapping region 1301approximately equals the width of the overlapping region 1302. In otherembodiments, the width of the underlapping region 1301 is about 95%,about 90%, about 80%, about 75%, about 60%, about 50%, about 40%, about30%, about 25%, about 15%, or about 10% of the width of the overlappingregion 1302. In some embodiments, the overlapping region 1302 is fromabout 5 cm to about 60 cm wide and the underlapping region 1301 is fromabout 5 cm to about 60 cm wide.

Variations in the profiling or contouring can be used to createdifferent stylistic or ornamental effects. For example, the module maybe moulded with a sinusoidal profile, as shown in FIG. 14, to simulateconcrete tiling; an angular profile, as shown in FIG. 15, to simulateweatherboarding; with relief features on its upper surface, as shown inFIG. 16, to simulate asphalt shingles; or with a variable upper surfacecontour to simulate slate tiling or wooden shakes. The continuousforming process allows a variety of different 30 surfaces to be producedwith the same equipment simply by swapping out the die faces on theforming machine as required.

The colour and visual properties of material feeds can be changed fairlyeasily also just by inputting different materials and additives(particularly colouring additives) at the feeding stage. This means thatit is possible to mass manufacture consecutive runs of different typesof product (e.g. a product simulating concrete tiles, a productsimulating slate tiles and a product simulating asphalt shingles)without significantly altering the equipment on the manufacturing line.

The modules may be installed in various vertical alignments as desiredand/or as permitted by the surface contouring. The offset verticalalignment shown in FIG. 17 gives the effect of traditional “tiled”roofing 1 while other alignments will also produce interesting visualand/or stylistic effects.

FIG. 18A shows a series of locator recesses 1801 within the fixingregion 1802 of a moulded module 1800 for locating nail or screw typefasteners. There are bosses 1803 (i.e. thickened sections of material)at the bottom of each recess to provide a strong area for the fastenershank to pass through, and these also create a flat surface 1804 to buttwith the building surface underneath the module. The sides of the recess1805 slope outward so that a hammer or pneumatic nail or staple gun canbe used to drive the fastener home without damaging the surroundingmodule material.

FIG. 188 shows there may be “starter” holes or locators 1801 within thefixing region 1802 for locating the fasteners 1806 (e.g., nails,staples, or screws) which attach the module to the building surface.These locators 1801 can be moulded features or extra surface markings.The purpose of such locators 1801 is to simplify installation by showinghow many fasteners 1806 are required and how far apart they ought bespaced. Furthermore, as shown in FIG. 18C, the locators 1801 may includerecesses that are adapted to fit conventional nail or screw gun heads1807. This provides easy alignment and accurate location of the fastenerfor the installer. There may be a layer of reinforcement materialcovering the fixing region of the module to prevent the module materialfrom tearing where it is penetrated by the fasteners, in which case thelocators can serve to ensure that the fasteners are positioned withinthe reinforced zone.

Once the module is fixed to the roof the head of the fastener should beflush with or sit below the top of the locator opening. As shown in FIG.19, this allows the overlapping region of a subsequently affixed moduleto sit flat over top of the first module.

The module may be formed with a convex precamber (as shown in FIG. 20)to apply a pre-load pressure to encourage the edges and bottom surfaceof the overlapping panel to contact firmly onto the underlapping panelwhen installed on a building. This also provides high thermalconductivity between the underlapping panel and the overlapping panel.Additionally, adhesive strips 111 (shown in FIG. 21A) running along thelength of each module can be used to connect one module to the surfaceof the next, creating a waterproof seal and stopping grit andparticulates from working their way under the roofing or cladding layer.There is also an advantage to securing those regions of the module whichare farthest from the fixing region so that the exposed portions of themodule cannot flap up in the wind and cause damage through fracture orbending stresses. This may be done with adhesive strips or by othermeans. f adhesive strips are used, it may be beneficial to have themcovered by release strips 113 for transport and storage (as showing inFIG. 21B). The release strips would be removed during installation.

The placement of the adhesive strip(s) on the module can vary. As shownin FIG. 22, in one embodiment, a first adhesive strip 121 is affixedalong the lower edge of the module on the back side of the mouldedmaterial layer, while a second 122 is affixed to the top side just belowthe line of the fixing region. Thus a series of modules can be arrangedas shown in FIG. 22, where the strip on the back side adheres to thestrip on the front side.

Alternatively, as shown in FIG. 23A, the adhesive strips can bepositioned so that both strips are on the front of the module; one atthe rear edge 131 and one just below the line of the fixing region 132.In this case the adhesive will secure two points of the module and willadhere directly to the substrate layer of the overlapping module. Afurther alternative or addition is to apply an adhesive paste to theregion 112 during installation.

As shown in FIG. 23B, the module may be pre-formed with a strip ofmaterial 133 on the upper surface of the underlapping region that servesas a weather-tight barrier when placed into contact with an adjacentmodule. This flexible strip of material 133 prevents the backflow ofwater or air in between the overlapping modules. A further alternativeor addition is to place a similar strip of polymeric material on thelower surface of the exposed region, to prevent water from penetratingbetween the two overlapping modules.

In one embodiment, a sequence of steps in the manufacture of the roofingand/or cladding product is to firstly prepare the module material forforming (which may involve bringing the material to a molten,semi-molten or pliable state), secondly, feeding the material to apressure forming zone, and thirdly, forming and setting the material asit advances through the pressure forming zone. While there are variousmethods of mixing and presenting the materials prior to forming, asuitable method is to deposit an extruded feed layer of a first material141 onto an advancing support surface of a continuous forming machine,and to subsequently introduce a further extruded feed layer of anothermaterial 142 overtop of this, as shown in FIG. 24. The first materialand the second material or additional may be the same or different, andmay be of the same or different form. Both materials then proceed as alayered feed 143 to the pressure forming zone 144, and are moulded intoa single module panel 145. The product can be manufactured so that thereare different features on the top of the moulded panel to those on thebottom by using different dies in the upper and lower rotating tracks146 of the CFT machine. The modules can also be manufactured using asingle material only.

Upon arrival at the pressure forming zone it may be that the secondmaterial feed entirely covers the first, however the feeds may bearranged so that only a portion of the first feed 151 is covered by thesecond 152 (as in FIG. 25). There may only be a thin strip of the secondmaterial or additional material on top of the first or second feed, andthe positioning of the strip across the width of the first feed canvary. These variations can be achieved during manufacture by changingthe positioning of the various extruders relative to each other and byaltering the width of the feeds.

In some embodiments, the first material layer has a width WI and athickness TI and the second material layer has a width W2 and athickness T2. In one embodiment, WI is wider than WII. In oneembodiment, WI and WII are of equal widths. In one embodiment, WII iswider than WI. In one embodiment, TI is thicker than TII. In oneembodiment, TI and TII are of equal thickness. In one embodiment, TII isthicker than TI. In one embodiment, WI and WII are within the range of 5centimetres to 3 metres. In one embodiment, TI and TII are within therange of 0.1 to 100 millimetres.

Additional material layers (whether extruded, roll fed, or otherwisepresented) can also be added prior to or after the forming process. Thisallows for the continuous forming of a multi-layered product, eachmaterial layer having a particular set of properties which areadvantageous to the product. In particular, it may be desirable to addone or more reinforcing layers to the product. Such layers may comprisea metal, cloth or fiberglass mesh, jute or other fabric, glass fibre,carbon fibre, aluminium sheet or a reinforcing polymer. These can belaid beneath, on top of, or in between the other material layers priorto the forming step, and may or may not undergo deformation during theforming step. The thickness of the module panel 153 produced will bedetermined in part by the materials selected and the number of layersfed in. In one embodiment the thickness of the panels may be within therange of about 0.5-55 mm.

The various layers of material may chemically bond together prior to orduring the forming step, however their ability to do so will dependentirely on the materials selected. Where the materials selected are notprone to chemical bonding, it may be necessary to assist adhesion with aplasma or adhesive layer; or to feed in a supplementary material with achemical affinity for both of the material layers. This can be appliedin-line as an interposing layer or deposit atop the first substratematerial feed prior to the introduction of the second. The variouslayers of material may also mechanically bond together due to thesurface finishes or features between the layers.

A similar product can be achieved by the segmental injection moulding ofthe roofing and/or cladding modules, however such a process has a muchslower output capacity. Large areas of product need to be produced forbuilding applications and it is desirable to be able to produce theselarge surface area products in high production volumes to make theprocess economical. Moreover, such a process would result in a productcontaining weld lines and injection moulding points. Weld lines areformed when two or more molten polymer flows meet during the injectionmolding process. This can occur when a polymer flow splits to go aroundan interruption (e.g., a post that forms a hole) and then rejoins, orwhen polymer melt fronts meet, from multiple injection points. This canalso occur when molten polymer meets a non molten polymer. Consequently,a visible weld line is observed and the adhesion/bond in this weld lineat the interface is weaker than the balance of the polymer within theproduct. Injection moulding points are the area of a product where theheated material was fed into the mold cavity. It is also difficult tomake a product comprising more than one layer of material usinginjection moulding, and injection moulding can produce colourdifferences or variations that affect the aesthetics of the finalproduct. On the other hand, the continuous forming machine can produceapproximately 5-60 m of product per minute, which makes it a preferableto use this production method over other processes which could be usedto manufacture a 3D polymer product. The continuous forming machine alsoproduces a product that lacks weld lines or injection moulding points,and optionally contains multiple layers of material.

A number of materials are suitable for use in the production of aroofing and/or cladding product by a continuous forming process; howeverit is most cost effective to produce the moulded panel from a foamedmaterial (e.g. foamed polycarbonate). Not only does this reduce theamount of raw material required for production, but also results in alightweight product. This can be advantageous in the retrofitting ofroofing or cladding to an existing building. For example, where there isa building with an existing but degraded roof, re-roofing can occur byplacing the new lightweight shingle directly over top of the existingshingle (usually asphalt shingle).

The foamed polycarbonate (or alternative substrate material) may beaccompanied by one or more additional materials to enhance theproperties of the product. A suitable material is ThermoplasticPolyurethane (TPU), which can be fed into the moulding process alongwith the polycarbonate as shown in FIG. 24. Foamed polycarbonate andsimilar materials are favoured in roofing products because they havefire retardant properties, but the addition of a TPU layer improves theperformance of the product because the TPU has better durability,physical properties and resistance to environmental wear. In particular,TPU is puncture resistant, tear resistant, and UV resistant, and willretain the aesthetic appeal of the product for a longer period of timecompared to polycarbonate alone.

The panel at its point of exit from the forming step is shown in FIG.26. The TPU layer (or a layer of alternative material) 161 is moulded ontop of the polycarbonate (or other foamed material) layer 162 to formthe body of the shingle module. While it is desirable to use as muchfoamed material as possible to reduce materials, in some embodiments,the TPU layer may cover the region 163 which extends from the lower edgeof the shingle up to a line above the fastener fixing region. This is sothat the areas of the shingle exposed to the elements will have gooddurability, and all of the areas of the shingle penetrated by fastenerswill have good tear resistance. An advantage to using TPU in thisinstance is that the TPU, once punctured, will tend to contract aroundthe shank of the fastener to make a watertight seal.

Other materials which may be used include (but are not limited to)polycarbonate (PC), general purpose polystyrene (GPPS), polymethylmethacrylate (PMMA), polyethylene terephthalate (PET), polyestermethacrylate (PEM), polypropylene (PP), high impact polystyrene (HIPS),acrylonitrile butadiene styrene (ABS), polyester (PES), polyamides (PA),polyvinyl chloride (PVC), polyurethanes (PU), polyvinylidene chloride(PVDC), polyethylene (PE), polytetrafiuoroethylene (PTFE),polyetheretherketone {PEEK) (polyetherketone), polyetherimide (PEI),Polyimide (PI), polylactic acid (PLA), high impact polystyrene,acrylonitrile butadiene styrene (ABS), acrylics, amorphous polymers,high density polyethylene (HDPE), polyethylene terephthalate {PET), lowdensity polyethylene (LOPE), linear low density polyethylene (LLDPE),medium density polyethylene (MOPE), cross linked polyethylene (PEX),Ethylene vinyl acetate {EVA), Ethylene vinyl alcohol (EVOH),thermoplastic elastomer (TPE), thermoplastic polyolefin (TPO),thermoplastic rubber (TPR), polypropylene (PP), Fluorinated ethylenepropylene (FEP), Polybutylene terephthalate (PBT), Polyoxymethylene(POM), Polyphenylene oxide (PPO), Polypropylene homopolymer (PP-H)Polypropylene copolymer (PP-C), silicon polymers, styrene-acrylonitrileresin (SAN) and thermoplastic rubber. The materials may be a blend ofany or all of these. The materials may also comprise additives toenhance properties such as resistance to fracture, impact, ultravioletlight, and thermal or tensile stresses. Materials which could also beconsidered in manufacture are various polystyrenes, nylons, acrylics,polyethylene, thermoplastic ethylene, polypropylene and phenolic, andcombinations of or containing these. No matter which materials arechosen, the materials must be compatible so that they do not delaminate.If the materials are not compatible, they may still be used; however, atie or bond layer must be introduced between them. Examples of tie orbond layers include, but are not limited to, ethylene vinyl acetate(EVA), thermoplastic polyolefin (TPO), thermoplastic elastomer (TPE),silicon adhesives, epoxy adhesives, and acrylic adhesives. One of skillin the art is capable of choosing materials in the appropriatecombinations to suit the purposes described herein.

In various embodiments, the roofing module is flame resistant, resistantto tearing (especially at puncture and attachment points), able to beeasily and cleanly cut with everyday tools to aid installation, able toendure environmental and UV exposure for over 20 years, able to endurecyclic freezing and thawing without failure, resistant to delaminationat temperatures of between −40 and 100 degrees Celsius, impact resistantto a reasonable extent, impenetrable by water even at fixing points, lowdensity, resistant to penetration and abrasion, colourfast, resistant tomicrobial attack, compatible with adhesives and made of materials whichare stable in high humidity and wet conditions and which retain theirpliability at high and low temperatures and which do not delaminate. Allof these factors come into play when choosing appropriate materials ormaterial combinations for the manufacture of the product. It is alsodesirable that the material(s) used are non-toxic, or that at least theupper layers of the product are (if a layered product is produced). Thisavoids the prospect of toxic contamination in the event that water is tobe collected from one or more building surfaces for subsequent use.

In some embodiments, the product may be produced from a recyclablematerial or several different recyclable materials. The combination ofmaterials chosen in the manufacture of the product is suitably one thatcan be recycled without first having to dismantle the product into itsconstituent materials.

It is also important to choose a material with a low co-efficient ofthermal expansion to avoid warping along the length of the product. Ifthe material undergoes too much movement once attached to the buildingsurface it may fail at or between the attachment points. Failure canalso be a problem if a layered product is produced with two or morematerials having vastly different thermal expansion co-efficients. Inone embodiment, as shown in FIGS. 39A-39B, thermal expansion andcontraction can be accommodated by moulding each module to have one ormore concertina-shaped features 291 that will expand or contract betweentwo fixing points 292.

In various embodiments, the roofing or cladding module may incorporateadditional properties or functionalities, including but not limited to:a photovoltaic functionality; and/or (iii) interconnectionfunctionalities of photovoltaic areas, as described in further detailbelow.

An alternative embodiment of the roofing and/or cladding product is onethat has all of the previously described features, along with severaladditional features that make the product suitable for use as part of athermal energy recovery system. The thermal energy can be obtained froma building surface that has been exposed to sunlight for a period oftime, although there are other less significant sources that maycontribute. The thermal energy can then be exhausted or transferred to apassing fluid flow (air being the most practical option) between theproduct and the building surface, and subsequently used elsewhere in thesystem.

A notable feature of this embodiment is that the building underlay formsone boundary of the airway path. This embodiment is different from box,round or other geometric closed cross section shapes e.g. Corflute® roofor similar products, which are segmented into confined zones for airflowthat can become blocked. The overall cost of materials is also reducedcompared to box, round or other geometric closed cross section shapedroofing materials, which contain a backing material to define aself-contained pathway for airflow. By contrast, this embodiment regardsthe whole roof as one large surface of airflow, with the cavity forairflow bounded on one side by the modules and the roofing underlay onthe other side.

As an example of such a system, FIG. 17 shows a roof assembly involvinga series of overlapping shingle modules. FIG. 18A shows an illustrativeembodiment of two modules from side on. The roofing underlay, such as aplywood surface and/or a weatherproofing, insulating or highlyreflective membrane 171, and the layer of roofing shingle will beslightly set off from the membrane so that there is a gap 181 to allowthe passage of an air stream between the two layers. The gap can bemaintained by features of shape integral to the shingle module moulding182 or by additional spacer/standoff components. Thus, the roof assemblyforms a single layer on top of the building underlay but the formedfeatures 182 (i.e., the profiled “feet” on the underside of theunderlapping region) make the stand-off for the air to pass through.FIGS. 28B and 28C illustrates a tile at the edge of the building surfaceand shows that a filter 184 can be placed between the tile and thebuilding underlay to allow for the passage of air from the outside intothe set off. It is most efficient to force the air in the directionwhich it would naturally travel as it gets hotter, i.e. from the bottomof the building surface to the top; however alternative embodimentswhere the air is drawn across the surface may also be conceived. Thewarm air can then be drawn through inlet spigots 172 near the upper edgeof the surface into a central manifold duct 173. The warm air can beexhausted directly to the atmosphere or used elsewhere in the building.

FIG. 29 shows how the energy from the warmed air can be used elsewherein the building. A fan 191 can be used to create airflow to pull the airinto the manifold duct. The warmed air can then be expelled from the fanand used as the working fluid of a heat exchanger 192 which can beemployed as required, for example in water heating 193 or airconditioning 194. Alternatively the hot air can be directly used forheating applications. A flap valve (not shown) may be installed torelease hot air from the manifold duct in the event that the fan fails.n some embodiments, the airflow is reversible, such that warm air can bedirected from the heat exchanger to the roof in order to, for example,melt snow or ice on the roof, purge residual moisture, or clear dust,dirt, or debris from the system. Different manifolds may also beincluded to direct warm air from one part of the roof to anotherdepending on the energy need. For example, air may be directed from asun-exposed portion of the roof to a shaded, snow-covered portion inorder to melt snow from that portion. Other variations would be readilyapparent to one of skill in the art.

In some embodiments, the speed of the fan is proportional to the thermalenergy received in a particular area of the roof. The fan speed can becontrolled in a variety of ways, including temperature sensors ortimers. In one embodiment, the fan speed is controlled by driving theelectric motor using one or more dedicated PV cells on the surface ofthe roof. Thus, the fan control will be directly related to how hotand/or intense the sun is on certain parts of the roof at differenttimes of the day. For example, a building surface may be divided intosections in which separate fans control airflow in each section, e.g. astandard house might have four sections and each would have its own fanwhich would increase in speed as the intensity of the sun increases onthat side of the roof and decrease in intensity as the sunlightintensity decreases. As such, the fans in the different sections will beincreasing and decreasing in speed depending on whether the particularsection is in full sun or is partially shaded.

In one embodiment, a thermal embodiment of the module can be moulded orprofiled with a raised patterning 211 in the underlapping region todefine a tortuous pathway above the actual or notional plane. Thiscauses turbulence in the flow of the forced fluid and thereforeincreases the convective heat transfer from the module to the flowingfluid. As described in detail in the next section, when PVfunctionalities are included on the module, the feet also provide apassageway for the wiring for electrical connection, e.g. to the PVcells, and allow for the incorporation of electronics into the shingle.The feet may be designed to also provide strength so that if a personwalks on the shingle it will not crush or fold under. The feet may alsobe designed to provide an even airflow across the entire airway space.The feet may also be designed to provide a minimal pressure drop betweenthe air intake and the air outlet. The feet may also be designed toprovide for the location and securing of cables and Tee fittings. Thefeet may also be designed to provide a pathway for the cables and Teefittings that has minimal obstruction. The pathway for the cables may bevertical, horizontal or diagonal.

There are many different patterns which will achieve this, including thealternating pattern of mesa-like projections shown in FIG. 31. Again theproportion of the shingle which is patterned may vary in comparison tothe size of the underlapping region. The projections on the underside ofthe module need not be the same across the entire width. In oneembodiment, the projections decrease in height as one moves across thewidth of the tile such that there is a taper between the buildingsurface and the underlapping region of the module. Therefore, when anoverlapping module is placed on top, it is kept parallel to the buildingsurface. For example, the projections may reduce in size from about 21mm to about 16 mm as one moves towards the back of the tile to make iteasier to fit the overlapping tile and keep the overlapping tileparallel to the building surface. The shape and layout of theprojections may also vary.

In another embodiment, the patterning is in the form of a corrugationbetween the module and the building surface. For example, the module canbe moulded into alternating parallel grooves and ridges.

FIG. 30 shows how the profiles may have chamfered sides 201 or otherfeatures of shape to prevent water from gravity pooling in thedepressions when the underlying surface on which the product isinstalled is an angled surface {for example a roof). A series of fineribs 212 moulded on the underside of the module, or roughened surfacetexture, could alternatively or additionally be used to createturbulence in the air flow. This will also create more surface area forconductive heat transfer from the module. In some embodiments, thegeometry of the ribs or texturing can be chosen to assist in heattransfer. For example, if the texture is, in profile, a series oftriangular peaks 213, this will allow more efficient heat transfer tothe passing air flow than if the texture is, in profile, a series ofsquare toothed projections.

As a further option, the surfaces which come into contact when lappingcould have complementary texturing on them to assist theirinterengagement; for example, as shown in FIG. 32. A thermallyconductive paste or adhesive may additionally or alternatively beapplied between the contact surfaces to enhance this, or the adhesivestrip feature may be thermally conductive or have a thermally conductivecomponent. In one embodiment, the upper and lower surfaces of the underand overlapping modules respectively have a serrated profile 221 capableof interlocking when the modules are in position. The serrations can beshaped so that they “wedge” into each other and exert some degree ofcompressive force against one another. The surface textures mightotherwise be splines, knurls, teeth or undulations of another type. Thetexturing brings the surfaces into better contact so that there is moresurface area to facilitate heat transfer between the lapping modules,and could also be used to aid in locating the modules when they areinstalled on a building surface.

Although foamed materials reduce the cost and weight of the product, theair inside the foam acts as a heat insulator. This can be advantageousif you want to stop heat from the sun being transferred into the ceilingcavity of the building, but it is not ideal for heat transfer in anenergy recovery system. Therefore the thermal embodiment of the roofingand/or cladding product may be adapted to increase its heat transfercapacity. In order to achieve a foamed material with high heatconductivity, thermally conductive particles (e.g. aluminium flakes) canbe introduced into a polymer prior to the forming process. The particleshelp to create a heat pathway through the material and increase theoverall thermal conductivity significantly. The particles may alsoprovide structural reinforcement to the material. For example, where amodule moulded from polycarbonate may have a thermal conductivity of 21W/mK, the same module moulded from a loaded polycarbonate blend having30% aluminium will have a thermal conductivity of 25 W/mK. A modulemoulded from 3% foamed polycarbonate may have an even lower thermalconductivity of 18 W/mK, but this can be improved to 24 W/mK with theaddition of 30% aluminium. The module material can be loaded with thethermally conductive substance prior to the manufacture of the module.

In order to prevent the final product from being too brittle, acompatiblising polymer, such as an ionomer, can be blended with themetal particles changing them from a reactive contaminant to areinforcement agent with elevated levels of thermal conductivity. It isdesirable to have some degree of elasticity to the formed material foruse in building product applications.

Another embodiment of the roofing and/or cladding product of the currentinvention is that which is adapted for use in a system to generateelectrical energy from solar power. Such products are generally referredto as building integrated photovoltaic products (“BIPV”). As shown inFIG. 33, a series or array of photovoltaic cells may be carried on theexposed region of the module so that they capture photons when installedon a building surface.

FIG. 34 shows a more detailed view of an energy generating module, whichmay comprise one or more moulded material layers 241, a solar arraylayer of connected photovoltaic cells 242, and an optional transparentsurface laminate layer 243. The energy generating module may alsocomprise bonding/encapsulation/tie layers to the front and/or back ofthe PV layer and may also contain layers to stop the corrosion of the PVlayer e.g. polyethylene, EFTE, etc. On the solar array layer, typicallyor optionally each of the photovoltaic cells in the row are connectedvia two bus strips which extend the entire length of the module; onerunning across the upper edges of the cells 244 and one running acrossthe lower edges 245. The advantage of this is that the bus stripscontact all of the cells so that only a single electrical junction foreach module need be connected to a main power take-off on installation.A further option is to have the bus strip material integrally mouldedinto the substrate panel during the forming process.

FIG. 21B shows an exploded view of all of the layers of an illustrativeBIPV product. The transparent laminate 243 is over a solar array layerof connected photovoltaic cells 242, which is over a moulded materiallayer 241. The release sheet 113 of an adhesive strip 121 are alsoshown. Optional adhesive, tie, or bonding layers (not shown) may beadded to the surface of any of the layers.

Where it is necessary to join two modules across the width of a surface(i.e. the electrical join is not at the main power take-off junction,but between two modules), the method shown in FIG. 35 can be used. Themodules may be positioned end on end and then an extra cell 251 can beplaced over the discontinuity to create an electrical connection betweenthe modules while also visually concealing the physical join line forimproved aesthetics.

The BIPV system may incorporate one or more “dummy” cells at variouslocations across the surface of the roof. In a suitable embodiment, thedummy cells will look identical to the rest of the PV cells but willhave no functionality. Because the dummy cell is not active, it can becut to fit the shape/space required and can be penetrated safely ifnecessary. As shown in FIG. 40, two “dummy” modules 301 are positionedin a lapping arrangement with a cutout for a pipe 302 emerging from thebuilding surface. BIPV modules 283 are shown on either side of the“dummy module. In addition, dummy cells may be positioned at the ends ofthe building surface or may be positioned at predetermined locations toprovide for the installation of various building features (satellitereceivers, antennas, pipes, etc.). One advantage of the dummy cells isthat they age identically to the rest of the PV cells and therefore theentire roof surface maintains consistent aesthetic features over time.In some embodiments, the dummy cells may be scribed with markings thatindicate that these cells can be safely penetrated, e.g., for theinstallation of hardware or for fire safety.

The modules may be suitably joined by an overlapping module (forweatherproofing) or an adhesive pad which extends across the join andcontacts the underside surfaces of both modules. t may also be necessaryto add a similar adhesive pad to the top side surfaces, or to smear thereverse side of the joining cell with an adhesive paste to secure thejoin.

While the PV cells could simply be placed on any top surface of amodule, in some embodiments the module is formed with a number of relieffeatures on its upper surface to locate and register the PV cells. Thesecan be more clearly seen in FIG. 36A. There are recessed panels orpockets 261 in the cell bearing portion of the shingle modules whichlocate each individual cell, and these are separated by raised orrecessed channels 262. The channels create the impression of “tiled”roofing, and generally add to the aesthetics of the product. Regions atthe top and bottom of the channels 263 provide space for the bus stripsto pass through between each pocket. It may be desirable that theseregions are less raised or lowered than the other parts of the channelso that the bus strip does not have to be bent excessively when it isadhered to the contours of the module substrate.

The exposed portion of the solar cell carrying module may be profiledwith two (or more) rows of pocketing so as to accommodate two (or more)rows of solar cells upon a single module. n such a case there willprovision to locate a set of bus strips for each row, or the profilingmay provide for the location of a shared bus strip(s) to be positionedbetween the rows.

The modules may be molded to accommodate various components of thephotovoltaic system. For example, as shown in FIG. 366, the uppersurface of the underlapping region may include channels 264 configuredto receive cables or wires of the photovoltaic array. Moreover, theupper surface of the underlapping region may also include formedcavities 265 configured to receive junction boxes 266, printed circuitboards (PCB), communication devices, cables, wires, buses, components,cells, or diodes, and the like of the photovoltaic array. Thus, themodules may contain all of the hardware and software required to connectand regulate the PV cells. Because there are no penetrations between thetwo overlapping modules, the assembly can be completely waterproofed.Furthermore, the upper surface of the exposed region may containscribings or markings, such as an impression or line corresponding tothe molded cavities, thus informing an installer or repair person thatvarious components are located in the space below. The upper surface ofthe underlapping region may also include formed markings 267 to indicatethe correct location of wires and Tee connections for wires, that arelocated in the pathway for airflow 181 underneath the underside of theunderlapping region.

With the modules installed as shown in FIG. 33 most of cell bearingportion of the module is exposed while the rest of the module, includingthe fixing region and fastening means is completely covered byneighbouring modules. This enables maximum power generation but stillprovides some degree of protection for the fastenings to reduce theirrate of degradation and corrosion. The upper electrical bus strip isalso protected by the front edge of the overlapping panel for bothweather and aesthetic reasons. Furthermore, because there are nopenetrations that traverse the entire thickness of the roofing material,this product overcomes the limitations of existing solar products, whichpenetrate the roof membrane with bolts, screws, or nails that must becaulked and can leak. Wires 231 can also run between the bottom of themodule and the weatherproof underlay without penetrating the underlay(as shown in FIG. 33).

The process by which the solar version of the roofing product can becontinuously manufactured is shown in FIG. 37. The first, second andthird steps of preparing, presenting and forming the module are the sameas those described previously, however the fourth step 271 is theapplication of the solar array and the optional fifth step 272 is theapplication of a laminate layer over the solar cells which may havebonding between layers or adhesive layers between them.

Once the module has been formed the PV cells can be deposited on top insuch a way as to be located by the relief features on the upper surface.FIG. 37 shows the PV cells being fed onto the substrate from acontinuous roll feed. In this case the upper and lower bus bars wouldneed to be associated with the cells in a prior step to form the roll.Another option is to deposit the cells individually into the pocketedrelief features of the substrate and to subsequently apply the bus bars(possibly separated by a spacing web) from a separate roll feed. Yetanother option is to feed the bus bars onto the substrate and thenoverlay the solar cells.

An optional step is to apply a transparent laminate 273 to protect thecells. t is convenient to pre-form (also by continuous moulding 274) andapply the laminate in-line, as shown in FIG. 36, so that the addition ofthis layer can occur without any increase in the overall productioncycle time. This can be laminated with some degree of electrostatic oradhesive binding to increase adhesion. While a variety of materials maybe suitable as the laminate, a suitable material is fluoropolymer.Ethylene tetrafluoroethylene (ETFE) is an example of an appropriatefluoropolymer, but other polymers able to remain optically transparentmay also be used. The fluoropolymer creates an essentially “selfcleaning” top surface so that performance of the PV cells is notinhibited by deposits of dirt and debris. Fluoropolymer is also verystable in ultraviolet light and usually retains its light transmittingcapacity for longer than glass, which is another commonly used materialin PV applications. It is preferable to choose a material which would beable to maintain light transmission during long periods (approximately10-25 years) of environmental exposure. The laminate is applied alsoover region 117 to cover parts of the panel which are not directlyexposed to light but which will receive reflected light. This laminatealso gives superior durability to the exposed outer area of the paneland may be used even without PV cells to provide greater long termdurability.

In another aspect, the present invention provides a building integratedphotovoltaic system which allows combined solar, ambient andsolar-generated heat to be collected and directed away from a buildingsurface and optionally used elsewhere. For instance, the photovoltaiccells of the energy generating module could heat up during operation. Aswell as potentially causing the interior of the building to heat up as aresult, the cells will also perform less efficiently as they growhotter. A further issue is that the material around the cells will tendto expand due to the heat and this can generate stresses and/or movementthat may eventually lead to product failure. Therefore, there is anadded advantage in combining the features of the BIPV product with thoseof the thermal product, and using the hybrid module as part of a systemwhich generates electrical energy while also allowing heat energy to betransferred away from the solar cells, recovered, and put to use asdesired. FIG. 38 shows a building on which the non-energy harvestingproduct 281, the thermal product 282 and the BIPV product 283 have allbeen installed at different regions of the same building according toenergy and cooling requirements.

The foregoing description of the invention includes preferred formsthereof. Modifications may be made thereto without departing from thescope of the invention.

What is claimed is:
 1. A roofing, cladding, or siding module comprising:an underlapping region and an exposed region, adjacent the underlappingregion, wherein the exposed region includes a top surface and a bottomsurface, and wherein the underlapping region is adapted to besubstantially covered by the bottom surface of the exposed region of anadjacent module when installed on a building surface; wherein theunderlapping region includes a top surface and a bottom surface, thebottom surface comprising a plurality of projections extending in adirection away from the top surface to define a pathway for air flowbetween the module and the building surface, wherein each of theplurality of projections is hollow and forms a cavity, and wherein theplurality of projections are located only within the underlappingregion, and a photovoltaic unit adapted to provide wireless powertransfer output disposed on the top surface of the exposed region, thephotovoltaic unit comprising: one or more photovoltaic cells thatgenerate electrical output, and at least one wireless power transfertransmitter electrically coupled to at least one of the one or morephotovoltaic cells to transfer the electrical output via wireless powertransfer.
 2. A roofing, cladding or siding module according to claim 1wherein the photovoltaic unit is for installation on a roof or asubstrate panel to serve as a roofing product.
 3. A roofing, cladding orsiding module according to claim 1 wherein the electrical output istransferred via wireless power transfer to a load and/or outputconductor.
 4. A roofing, cladding or siding module according to claim 3wherein the wireless power transfer is via capacitive coupling wherebythe at least one wireless power transfer transmitter forms a capacitorwith a wireless power transfer receiver coupled to (or for coupling to)the load and/or output conductor.
 5. A roofing, cladding or sidingmodule according to claim 4 wherein the at least one wireless powertransfer transmitter comprises a capacitor plate.
 6. A roofing, claddingor siding module according to claim 5 wherein the capacitor plate hassurface texturing.
 7. A roofing, cladding or siding module according toclaim 6 wherein the surface texturing is nanoscopic and/or microscopicsurface texturing.
 8. A roofing, cladding or siding module according toclaim 1 wherein there are two or more photovoltaic cells coupledtogether to generate the electrical output, wherein the photovoltaiccells are coupled together via wireless power transfer using the atleast one wireless power transfer transmitter or a second wireless powertransfer transmitter.
 9. A roofing, cladding or siding module accordingto claim 1 comprising a plurality of formed surfaces moulded from one ormore polymeric materials, wherein each of the formed surfaces comprisethree dimensional surface features, and wherein the formed surfaces arejoined without weld lines or injection moulding points.
 10. A roofing,cladding or siding module according to claim 1 further comprising: a fanadapted to induce the air flow.
 11. A roofing, cladding or siding moduleaccording to claim 1 wherein the plurality of projections are from aplane of the underlapping region.
 12. A roofing, cladding or sidingmodule according to claim 1 wherein the plurality of projectionscooperatively define a tortuous pathway.
 13. A roofing, cladding orsiding module according to claim 1 wherein the plurality of projectionsare feet.
 14. A roofing, cladding or siding module according to claim 1wherein the plurality of projections comprises raised patterning.
 15. Aroofing, cladding or siding module according to claim 1 wherein theplurality of projections comprises at least one of: alternating groovesand ridges, ribs, or roughened surface texture.
 16. A roofing, claddingor siding module according to claim 1, wherein at least one of theplurality of projections is integrally formed with the bottom surface ofthe underlapping region.